Senior Tooling and Manufacturing Engineer

Senior Tooling and Manufacturing Engineer

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Firehawk Aerospace is pioneering the development of additively manufactured rocket propulsion systems, combining advanced manufacturing techniques with innovative engineering to deliver safer, more reliable, and cost-effective solutions for space exploration and defense. We are seeking a talented Tooling Engineer to join our team and help shape the future of rocket motor manufacturing.

As a Senior Tooling Engineer at Firehawk Aerospace, you will play a critical role in developing manufacturing equipment and processes for our rocket motor systems. You will work closely with the design, production, and quality teams to ensure efficient, safe, and scalable factory operations. This position requires a hands‑on approach to problem‑solving, a strong understanding of manufacturing principles, and a commitment to continuous improvement.

• Design tooling solutions to support new production lines and R&D efforts, ensuring manufacturability and scalability
• Collaborate with suppliers to develop and implement automated production solutions, including automated inspection processes (machine vision and radiographic inspection equipment)
• Provide estimates for tooling projects and support capital budget planning activities
• Support EH&S initiatives for increased safety and ergonomics across all sites and production lines
• Support hardware engineering teams in transitioning products from development to production
• Lead Design for Manufacturing and Assembly (DFMA) initiatives to optimize product designs for manufacturability and efficiency
• Develop and execute validation and qualification plans for new tooling and equipment
• Identify opportunities for process improvements to enhance production efficiency, reduce cycle times, and improve product quality
• Create and maintain tooling documentation, support manufacturing engineers in production planning activities and creation of work instructions
• Collaborate with automation suppliers to ensure that tooling solutions meet technical requirements, quality standards, and delivery schedules
• Ensure tooling and manufacturing processes comply with safety, environmental, and regulatory requirements
• Support routine maintenance and repair planning for factory equipment and tooling
• Support hardware engineering in design and fabrication of test‑specific tooling and fixtures

• Bachelor’s degree in Mechanical, Manufacturing, Industrial Engineering, or related field
• 6+ years of experience in manufacturing engineering or production support in aerospace, defense, or similar industry
• Extensive design experience using 3D modeling software (PTC Creo preferred)
• Experience in conceptual design of complex mechanical assemblies
• Fabrication, integration and implementation of fixtures
• Advanced knowledge of manufacturing principles, including lean manufacturing, Six Sigma, and DFMA
• Experience with configuration management and document change control using PTC Windchill
• Experience with manufacturing process documentation, including work instructions and process flow diagrams
• Strong problem‑solving skills and the ability to perform root cause analysis and implement corrective actions
• Experience with additive manufacturing (3D printing) processes and their application in production environments
• Excellent communication skills, with the ability to work effectively in cross‑functional teams
• Self‑starter who is comfortable working with limited direction
• Ability to obtain and maintain a DOD‑issued security clearance
• Ability to travel (up to 10%)

• Experience in the manufacturing of rockets or weapon systems and components
• Structural analysis experience (ANSYS)
• Experience with safe handling of explosives or other hazardous material
• Proficiency with Deltek Costpoint or similar ERP system
• Experience planning and implementing automation and robotics in manufacturing processes
• Robust knowledge of machine shop processes and equipment, and experience interfacing with machine shop personnel
• Experience transitioning…